How to Cut Perspex: A Complete DIY Guide

Perspex (acrylic) is one of the most DIY-friendly plastics out there — you can cut it with tools you almost certainly already own. The key is knowing which method suits your thickness and shape, and how to avoid the two big problems: cracking and chipping.

Here's the EXP Plastics workshop guide to cutting Perspex at home.

Method 1 — Score and snap (best for thin sheets)

Up to about 5mm thick, the easiest way to cut Perspex is with a Perspex scoring knife or a sharp utility knife.

1. Mark your cut line with a fine permanent marker.
2. Clamp a steel ruler or straight edge along the line.
3. Score firmly along the line 6–10 times until you have a clear groove.
4. Position the score over the edge of a workbench and snap downward firmly.

Tip: always leave the protective film on while cutting — it stops the surface scratching.

Method 2 — Jigsaw (best for curves and thicker sheets)

For curves, holes or sheets thicker than 5mm, a jigsaw is your friend.

• Use a fine-tooth metal-cutting blade (10–14 TPI).
• Set the saw to a slow-to-medium speed — too fast and the blade melts the plastic.
• Apply gentle, steady pressure. Let the blade do the work.
• Support the sheet on both sides of the cut to stop vibration.

Method 3 — Circular saw or table saw (best for long straight cuts)

For long straight rips on thicker sheets, a circular or table saw works well — provided you use a fine-tooth (60+ teeth) blade designed for non-ferrous metals or plastics. Slow and steady is the rule, with the protective film left in place.

Finishing the edges

Cut edges will look frosted. Depending on what you need:

• Sand with progressively finer wet-and-dry paper (240, 400, 800, 1200 grit) for a smooth matte finish.
• Flame polish with a propane torch for a glass-like shine — practise on offcuts first.
• Diamond polish on a buffing wheel for the ultimate finish.

Avoiding cracks

1. Always drill a starter hole inside any cut-out before introducing the saw.
2. Use a plastic-rated drill bit, or grind the front edge off a normal HSS bit.
3. Keep the sheet supported and clamped near (but not on) the cut line.
4. Don't force tools through the material.

Or let us do it

Don't have the time, tools or confidence? EXP Plastics offers Perspex cut to size from our Gold Coast workshop, often while you wait. Call 07 5620 1038 or drop us a line.